Shoe upper made of a light-weight waterproof laminate

ABSTRACT

A shoe upper has at least one part thereof made of a waterproof laminate which includes an inner foamed layer made of a pliable semi-flexible foam material, an intermediate layer of woven fabric material bonded to the inner foamed layer, an outer film layer made of a material which is waterproof and which has high wear-resistance, and a layer of adhesive applied to the intermediate layer to bond the intermediate layer to the inner foamed layer and the outer film layer. The adhesive is flexible and penetrates through the intermediate layer to render the latter water-impervious. The laminate is light-weight and possesses excellent wear-resistance and tear strength. The margins of the laminate are provided with stitch seams.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention relates to a shoe, more particularly to a shoehaving an upper made of a soft and light-weight waterproof laminate.

[0003] 2. Description of the Related Art

[0004] Common materials available for making shoe uppers includeleather, textile materials, vulcanizable rubber sheets, and variousplastic materials. Among these go materials, leather, vulcanizablerubber and injection-moldable plastic materials are usually used inmaking toe caps and counter sections of shoes for mountain climbing,hiking and hunting. However, while leather is soft, it is not waterproofand is prone to wear and destruction. Vulcanizable rubber is heavydespite of its waterproof and high abrasion-resistant characteristics.Injection moldable plastic materials may be waterproof but do not havesufficient wear-resistance and softness. In addition, leather andvulcanizable rubber are typically monotonous and are difficult to betreated for surface modifications to improve the appearance and colorthereof. If they are to be patterned, it is necessary to employ anexpensive patterning process, such as transfer printing, which is alsotime-consuming.

[0005] Foams, such as EVA foams, are widely used in making midsoles fortheir soft and light-weight properties. It is known in the art to make amidsole from a laminate which includes an EVA foam, a fabric layercovering the EVA foam and a waterproof PU film overlying the fabricLayer. Since the laminate in the midsole is generally formed as a thickpad cushion rather than a sheet and since foams are considered to beeasily tearable when being sewn, the prior art never suggests that thelaminate be sewn and lasted to form a shoe upper.

SUMMARY OF THE INVENTION

[0006] An object of the present invention is to provide an upper with awaterproof laminate which can be easily patterned and colored and whichis light-weight but still possesses excellent wear-resistance and isdurable enough to bear against stitching stress.

[0007] Accordingly, a shoe according to the present invention comprisesan upper which includes a plurality of parts assembled and stitchedtogether, at least one of the parts being made of a waterproof laminate.The laminate includes: a light-weight inner foamed layer made of apliable semi-flexible foam material; an intermediate layer of wovenfabric material bonded to the inner foamed layer; an outer film layermade of a material which is waterproof and which has highwear-resistance; and a layer of adhesive applied to the intermediatelayer to bond the intermediate layer to the inner foamed layer and theouter film layer, the adhesive being flexible and penetrating throughthe intermediate layer to render the intermediate layerwater-impervious, wherein the part made of the laminate has marginsprovided with stitch seams.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Other features and advantages of the present invention willbecome apparent in the following detailed description of the preferredembodiment with reference to the accompanying drawings, of which:

[0009]FIG. 1 is a perspective view of a shoe incorporating a laminateaccording to the present invention;

[0010]FIG. 2 is a cross-sectional view of the laminate according to thepresent invention;

[0011]FIG. 3 is a toe cap blank formed from the laminate of FIG. 2; and

[0012]FIG. 4 is a counter blank formed from the laminate of FIG. 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0013] Referring to FIGS. 1 and 2, a shoe 1 incorporating the presentinvention is shown. The shoe 1 includes a toe cap 11, a counter 12 and avamp section 13 connected between the toe cap 11 and the counter 12. Thetoe cap 11 and the counter 12 are made of a laminate 3 which embodiesthe present invention.

[0014] As best shown in FIG. 2, the laminate 3 includes a soft andlight-weight inner foamed layer 31, an intermediate layer 32 of wovenfabric material, and an outer film layer 33. The laminate 3 mayadditionally include a fabric lining (not shown) to cover the innerfoamed layer 31. The fabric lining may be fabricated from a woven ornonwoven fabric material. The laminate 3 is waterproof and can bestitched and formed into a desired shape in a mold.

[0015] During the production of the laminate 3, an adhesive 34 isapplied to the intermediate layer 32. The intermediate layer 32 togetherwith the adhesive 34 is first attached to the outer film layer 33 andthen adhered to the inner foamed layer 31. Upon application of alaminating pressure, the adhesive 34 penetrates through the intermediatelayer 32, thus saturating the woven fabric material of the intermediatelayer 32. The adhesive 34 not only renders the woven fabric materialwater-impervious but also bonds the intermediate layer 32 to the outerfilm layer 33 and the inner foamed layer 31. The adhesive 34 is aflexible adhesive, such as, a two-component polyurethane-based adhesive.

[0016] The woven fabric material of the intermediate layer 32 isentirely covered by the inner foamed layer 31 and the outer film layer33 so that the woven fabric material is prevented from coming intocontact with external water or moisture. If the laminate 3 is providedwith a fabric lining at the inner side of the inner foamed layer 31, thefabric lining will be embedded in an inner surface of the inner foamedlayer 31 due to the pressure and heat applied during the laminatingprocess.

[0017] The inner foamed layer 31 is made of a pliable semi-flexible foammaterial which is preferably selected from the group consisting ofethylene vinyl acetate copolymer (EVA), expandable polyethylene (EPE),and neoprene. The foamed layer 31 is of light-weight, pliable andinexpensive and can provide warmth and a feeling of comfort to thewearer. The thickness of the inner foamed layer 31 is preferably 1-10mm.

[0018] The outer film layer 33 is made of a material which is waterproofand has good wear-resistance. Preferably, the outer film layer 33 ismade of a material which is selected from the group of consisting of apolyurethane film and a polyvinyl chloride film. In addition, the outerfilm layer 33 is preferably transparent so as to present the texture ofthe woven fabric material of the intermediate layer 32 through the outerfilm layer 33. The thickness of the outer film layer 33 is preferably0.3 mm-1 mm, more preferably, 0.5 mm. If the outer film layer 33 isexcessively thick, the flexibility of the laminate 3 will be reduced,and the formability and the stitching characteristics of the laminate 3will be affected adversely. If the thickness of the outer film layer 33is not thick enough, the wear-resistance of the laminate 3 will bereduced.

[0019]FIGS. 3 and 4 show a toe cap blank 41 and a counter blank 42 whichare formed by tailoring the laminate 3. The toe cap blank 41 is providedwith embossed patterns 411, a stitch groove 412 of substantiallyL-shaped cross-section, and a stitch groove 413 of substantiallyU-shaped cross-section. Similarly, the counter blank 42 is formed withembossed patterns 421, stitch grooves 422 having a substantiallyL-shaped cross-section, and a stitch groove 423 of substantiallyU-shaped cross-section. The toe cap 11 and the counter 12 of the shoe 1are obtained by lasting the toe cap blank 41 and the counter blank 42.The stitch grooves 412, 413, 422 and 423 are provided to receive andprotect stitch seams 15 (see FIG. 1).

[0020] In an example of the laminate 3, the inner foamed layer is madeof ethylene vinyl acetate copolymer, and the outer film layer is apolyurethane film. Despite of the light-weight property, the laminate 3possesses excellent wear-resistance and tear strength and is strongenough to bear stress arising from sewing stitches.

[0021] Since the laminate 3 can be patterned via an embossing processwhich is easy and inexpensive, the patterning of the laminate 3 does notrequire an expensive process, such as transfer printing. The laminate 3can be formed with stitch grooves to receive and protect sewingstitches. In addition to the use of the laminate 3 as a material for ashoe upper, the laminate 3 may also be used in making parts of garmentswhere wear-resistance is necessary.

[0022] While the present invention has been described in connection withwhat is considered the most practical and preferred embodiment, it isunderstood that this invention is not limited to the disclosedembodiment but is intended to cover various arrangements included withinthe spirit and scope of the broadest interpretation so as to encompassall such modifications and equivalent arrangements.

I claim:
 1. A shoe comprising an upper that includes a plurality ofparts assembled and stitched together, at least one of said parts beingmade of a waterproof laminate which includes: a light-weight innerfoamed layer made of a pliable, semi-flexible foam material; anintermediate layer of woven fabric material bonded to said inner foamedlayer; an outer film layer made of a material which is waterproof andwhich has high wear-resistance; and a layer of adhesive applied to saidintermediate layer to bond said intermediate layer to said inner foamedlayer and said outer film layer, said adhesive being flexible andpenetrating through said intermediate layer to render said intermediatelayer water-impervious, wherein said part made of said laminate hasmargins provided with stitch seams.
 2. The shoe as claimed in claim 1,wherein said outer film layer is transparent.
 3. The shoe as claimed inclaim 1, wherein said pliable, semi-flexible foam material of said innerfoamed layer is selected from the group consisting of ethylene vinylacetate, expandable polyethylene, and neoprene.
 4. The shoe as claimedin claim 1, wherein said material of said outer film layer is selectedfrom the group consisting of a polyurethane film and a polyvinylchloride film.
 5. The shoe as claimed in claim 1, wherein said parts ofsaid upper includes a toe cap section and a counter section, each ofsaid toe cap section and said counter section being made of saidlaminate.
 6. The shoe as claimed in claim 1, wherein said laminate isformed with stitch grooves at said margins, said stitch seams beingdisposed along said stitch grooves.
 7. The shoe as claimed in claim 1,wherein said laminate is embossed to present an embossed pattern at saidouter film layer.
 8. The shoe as claimed in claim 1, wherein said innerfoamed layer is made of ethylene vinyl acetate copolymer, said outerfilm layer is a polyurethane film, and said adhesive is apolyurethane-based adhesive.